A new system to produce intraoperatively custom femoral prosthesis from measurements taken during the surgical procedure.

A system has been developed that allows the surgeon to match a prosthesis to any femoral cavity. The surgeon may choose how and where it will preferentially fit. The surgeon does not have to create a cavity to suit a premade prosthesis. The system is based on a novel technique for making a mold of the prepared femoral cavity. This is accurately and thoroughly measured using a laser. An implant is designed and manufactured while the operation is in progress using state-of-the-art computer and machining techniques. All important parameters such as neck length, offset, and anteversion are fully variable intraoperatively. To date, more than 800 consecutive procedures have been carried out. In a limited trial, no subjective difference was found with a cemented Charnley total hip arthroplasty at one year. It currently takes about 40 minutes to manufacture the implant and make it available in the operating room, and this time is being continually reduced. Using a femur first approach, operating time is not greatly extended. In the future, perhaps the operating time will not be extended at all. All data including cavity geometry are centrally recorded for analysis.